Flexibilisation of electrified industrial processes - An analysis of the technical and economic challenges from a company and system perspective

The decarbonisation of energy-intensive industry poses major challenges for energy supply: an increasing demand for electricity coincides with a power generation that is more dependent on wind and sun and limited grid capacities. Flexibilisation of supply in terms of time and space, storage solutions and adapted demand are therefore becoming increasingly important. What role can the flexibilisation of electrified industrial processes play in this?

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Background

On behalf of the Competence Centre for Climate Protection in Energy-Intensive Industries (KEI), the Fraunhofer Institute for Systems and Innovation Research and the Institute for Industrial Furnaces and Heat Engineering at RWTH Aachen have conducted a comprehensive study of the potential and challenges for making industrial processes more flexible. The study analyses the effects of industrial flexibility options on the energy system and compares them with other options such as controllable generators, grids and storage. Case studies from the steel, aluminium, glass, cement and chemicals industries reveal technical and economic challenges.

Results

To date, flexibilisation has seen little use for energy usage and production processes in the primary industries. Capacity utilisation is high in existing production facilities, which are optimised for continuous operation.
While a greater degree of flexibilisation is technically possible for contemporary production processes and future electrified process heat systems, it cannot be implemented without additional costs.
In manufacturing, load flexibilisation can contribute to the integration of renewable energy sources into the overall energy system. At the same time, a realistic estimation of the available options is needed and industrial flexibilities should be evaluated in context with other options.
Hybrid energy supply is a key technology that increases flexibility while also facilitating the transformation. Technologies are available for widespread deployment in many industries.
The current regulatory framework inhibits flexibilisation. Electricity network charges should be aligned with the requirements of an energy system based on wind power and PV. Developing the potential for industrial flexibility requires a clear strategy from policymakers as well as business investment. A strategy for increasing energy flexibility should exploit synergy effects with other policy areas.

Publications

Duration

October 2022 – August 2024

Clients

Kompetenzzentrum Klimaschutz in energieintensiven Industrien (KEI)

Partners

Fraunhofer ISI
Institut für Industrieofenbau und Wärmetechnik, RWTH Aachen

Project